Heat Units Using a Solid Fuel Capable of Undergoing an Exothermic Metal Oxidation-Reduction Reaction Propagated without an Igniter

ABSTRACT

A heating unit comprising an electrically conductive substrate. A solid fuel layer comprising a metal reducing agent, a metal containing oxidizing agent and a binder is coated on a surface of the substrate, the solid fuel layer having a solid fuel surface spaced from the substrate. A first electrode coupled to the substrate. A second electrode coupled to the solid fuel surface. A power supply is configured to be selectively coupled to the first and second electrodes to provide a voltage between the metallic substrate and the solid fuel surface. The voltage acts to propagate an exothermic metal oxidation-reduction reaction without the use of an igniter.

RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 13/217,385, filed Aug. 25, 2011, entitled “Heat Units Using a Solid Fuel Capable of Undergoing an Exothermic Metal Oxidation-Reduction Reaction Propagated without an Igniter”, which application claims priority to U.S. Provisional Patent Application Ser. No. 61/377,377, filed Aug. 26, 2010, entitled “Heat Units Using a Solid Fuel Capable of Undergoing an Exothermic Metal Oxidation-Reduction Reaction Propagated without an Igniter”. The entire disclosures of which are hereby incorporated by reference. Any disclaimer that may have occurred during the prosecution of the above-referenced applications is hereby expressly rescinded, and reconsideration of all relevant art is respectfully requested.

TECHNICAL FIELD

This disclosure is directed to heating units capable of rapid heating and to articles and methods employing such heating units, and more particularly to heating units using a solid fuel capable of undergoing an exothermic metal oxidation-reduction reaction propagated without an igniter.

BACKGROUND

Self-contained heating units using a solid fuel capable of undergoing an exothermic metal oxidation-reduction reaction are known. Such devices use a metal reducing agent and a metal containing oxidizing agent typically in combination with an additive such as a binder coated on the surface of an electively conductive substrate. Various embodiments of self-contained heating units utilizing such solid fuel layers are described in Hale, U.S. Patent Publication No. 2004/0234914, the entire disclosure of which is hereby incorporated by reference. The solid fuel capable of undergoing exothermic metal oxidation-reduction reaction has proven useful, in particular as part of a drug delivery device, because of the ability of the solid fuel to heat the substrate to several hundred degrees Celsius very rapidly, i.e., on the order of seconds and fractions of seconds. This rapid heating to a high temperature is useful for producing high purity aerosols of drugs coated on or in heat exchange relationship with the heat units. However, heat units using solid fuels capable of undergoing exothermic metal oxidation-reduction reaction have required actuation by one of a variety of ignition systems. Such ignition systems include, but are not limited to, resistive heating igniters, resistive heating with an arc, optical, percussive igniters. While each of these various starters have advantages and drawbacks with respect to other starter options, it would be advantageous if no starter or igniter was required to initiate the metal oxidation-reduction reaction. Eliminating the igniter would minimize the components and manufacturing processing steps required to build heating units and dramatically reduce the cost while simultaneously increasing the safety and reliability of the heating units.

The present invention is directed toward overcoming one or more of the problems discussed above.

SUMMARY

A first aspect is a heating unit comprising an electrically conductive substrate. A solid fuel layer comprising a metal reducing agent, a metal containing oxidizing agent and a binder is coated on a surface of the substrate, the solid fuel layer having a solid fuel surface spaced from the substrate. A first electrode is coupled to the substrate. A second electrode is coupled to the solid fuel surface. A power supply is configured to be selectively coupled to the first and second electrodes to provide a voltage between the metallic substrate and the solid fuel surface. The voltage (and a small amount of current) acts to propagate an exothermic metal oxidation-reduction reaction without the use of an igniter.

Another aspect is a drug supply unit comprising an electrically conductive substrate having an exterior surface and an interior surface and a solid fuel layer comprising a metal reducing agent, a metal containing oxidizing agent and a binder coated on the interior surface of the substrate, with the solid fuel layer having a solid fuel surface spaced from the substrate. A first electrode is coupled to the substrate and a second electrode is coupled to the solid fuel surface. A power supply is configured to be selectively coupled to the first and the second electrodes to provide a voltage between the metallic substrate and the solid fuel surface to propagate an exothermic metal oxidation-reduction reaction within the enclosure. A drug is disposed on a portion of the exterior surface of the substrate.

A further aspect is an aerosol drug delivery device comprising a housing defining an airway and a heating unit as described above disposed within the airway. A drug is disposed on another surface of the substrate whereby upon coupling of the first and second electrodes to the battery the solid fuel is ignited to vaporize the drug.

Yet another aspect is a method of making a heating unit comprising coating a portion of the interior surface of a conductive substrate with a slurry of solid fuel comprising a metal reducing agent, a metal containing oxidizing agent and an inorganic binder. The slurry is solidified and a first electrode is coupled to the conductive substrate and a second electrode is coupled to a surface of the solid fuel.

It is to be understood that both the foregoing general description and the following detailed description are explanatory and are not restrictive of embodiments in the scope of the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic elevation view of a first embodiment of a heating unit without an igniter comprising a fuel layer disposed on a surface of a substrate;

FIG. 2 is another embodiment of a heating unit without an igniter wherein the heat unit has an enclosure comprising a substrate with a solid fuel layer disposed on an interior surface of the substrate;

FIG. 3 is an embodiment of a heating unit without an igniter with a solid fuel layer sandwiched between two conductive substrates;

FIG. 4 is an embodiment of a heating unit without an igniter with a substrate having multiple discrete fuel layers selectively engaged by an electrode;

FIG. 5 is a schematic representation of a drug delivery device utilizing a heating unit of FIG. 1;

FIG. 6 is a bar graph illustrating various formulations of solid fuel;

FIG. 7 is a chart indicating variability of resistance of the formulations of FIG. 6 that did or did not activate;

FIG. 8 is a chart further illustrating variability of resistance of select formulations of solid fuels that did or did not activate;

FIG. 9 is a chart illustrating the effect of surface area of a solid fuel layer on resistance;

FIG. 10 is a chart illustrating activation of varying solid fuel thickness with different applied voltages;

FIGS. 11A-11C are graphs of activated solid fuels showing capacitance versus solid fuel thickness at various voltages;

FIG. 12 is a graph of solid fuel thickness versus the capacitance of a capacitor at varying capacitor voltages; and

FIG. 13 is a chart of successfully actuated solid fuels of indicated thickness using capacitors of indicated voltages and capacitance applying the indicated energy.

DETAILED DESCRIPTION

Unless otherwise indicated, all numbers expressing quantities of ingredients, dimensions reaction conditions and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about”.

In this application and the claims, the use of the singular includes the plural unless specifically stated otherwise. In addition, use of “or” means “and/or” unless stated otherwise. Moreover, the use of the term “including”, as well as other forms, such as “includes” and “included”, is not limiting. Also, terms such as “element” or “component” encompass both elements and components comprising one unit and elements and components that comprise more than one unit unless specifically stated otherwise.

A basic embodiment of a heating unit 10 is depicted in FIG. 1. The heating unit 10 comprises an electrically conductive substrate 12 which can be formed from known electrically conductive materials, including, but not limited to, metals, such as aluminum, iron, copper, stainless steel and the like, as well as various alloys thereof. Some conductive ceramics and polymers may also be suitable substrate materials. A substrate can be formed of one or more of these materials and certain embodiments can have a multilayer structure. For example, the substrate can comprise one or more films or coatings or multiple sheets or layers of material. A substrate can be of any appropriate geometry, including rectangular configurations illustrated herein. A substrate can have any suitable thickness. In certain embodiments, such as illustrated in FIG. 2, the substrate 12 may include an interior surface 14 and an exterior surface 16 and the substrate 12 can be incorporated into a sealed container 18 containing a solid fuel or reactant 20. In other embodiments (not shown) the solid fuel can be disposed on two adjacent areas of a surface of a substrate and the adjacent areas are folded over with an electrical lead therebetween. The edges of the substrate are then sealed together to form a two side reactant heat unit.

An article or object can be placed adjacent or in contact with the exterior surface 16 to receive conducted heat to achieve a desired action, such as forming or heating of a solid or fluid object, effecting a further reaction, or causing a phase change. For example, the conductive heat can effect a phase change on a compound in contact directly or indirectly with the exterior surface 16.

The components of the solid fuel can react in an exothermic reaction to produce heat. For example, the solid fuel can react in an exothermic oxidation-reduction reaction. An oxidation-reduction reaction refers to a chemical reaction in which one compound gains electrons and another compound loses electrons. The compound that gains electrons is referred to as an oxidizing agent, and the compound that loses electrons is referred to as a reducing agent. An example of an oxidation-reduction reaction is a chemical reaction of a compound with molecular oxygen (O₂) or an oxygen-containing compound that adds one or more oxygen atoms to the compound being oxidized. During the oxidation-reduction reaction, the molecular oxygen or the oxygen-containing compound is reduced by the compound being oxidized. The compound providing oxygen acts as the oxidizer or oxidizing agent. The compound being oxidized acts as the reducing agent. Oxidation-reduction reactions can be exothermic, meaning that the reactions generate heat. An example of an exothermic oxidation-reduction reaction is the thermite reaction of a metal with a metal oxidizing agent. In certain embodiments, a solid fuel can comprise a metal reducing agent and an oxidizing agent, such as for example, a metal-containing oxidizing agent.

In some embodiments, the metal reducing agent and the oxidizing agent can be in the form of a powder. The term “powder” refers to powders, particles, prills, flakes, and any other particulate that exhibits an appropriate size or surface area to sustain self-propagating ignition. For example, in some embodiments, the powder can comprise particles exhibiting an average diameter ranging from 0.1 μm to 200 μm.

In some embodiments, a metal reducing agent can include, but is not limited to molybdenum, magnesium, calcium, strontium, barium, boron, titanium, zirconium, vanadium, niobium, tantalum, chromium, tungsten, manganese, iron, cobalt, nickel, copper, zinc, cadmium, tin, antimony, bismuth, aluminum, and silicon. In certain embodiments, a metal reducing agent can include aluminum, zirconium, and titanium. In some embodiments, a metal reducing agent can comprise more than one metal reducing agent.

In some embodiments, an oxidizing agent can comprise oxygen, an oxygen based gas, or a solid oxidizing agent. In some embodiments, an oxidizing agent can comprise a metal-containing oxidizing agent. In some embodiments, a metal-containing oxidizing agent includes, but is not limited to, perchlorates and transition metal oxides. Perchlorates can include perchlorates of alkali metals or alkaline earth metals, such as, but not limited to, potassium perchlorate (KClO₄), potassium chlorate (KClO₃), lithium perchlorate (LiClO₄), sodium perchlorate (NaClO₄), and magnesium perchlorate [Mg(ClO₄)₂]. In some embodiments, transition metal oxides that function as oxidizing agents include, but are not limited to, oxides of molybdenum, such as MoO₃, iron, such as Fe₂O₃, vanadium (V₂O₅), chromium (CrO₃, Cr₂O₃), manganese (MnO₂), cobalt (CO₃O₄), silver (Ag₂O), copper (CuO), tungsten (WO₃), magnesium (MgO), and niobium (Nb₂O₅). In some embodiments, the metal-containing oxidizing agent can include more than one metal-containing oxidizing agent. Metal oxides having a melting point less than 1500° C. are believed suitable for the various embodiments disclosed herein.

In some embodiments, the metal reducing agent forming the solid fuel can be selected from zirconium, titanium and aluminum, and the metal-containing oxidizing agent can be selected from MoO₃ MnO₂ and Fe₂O₃.

In some embodiments, a solid fuel can comprise additive materials to facilitate, for example, binding of the metal containing oxidizing reagent and reducing agent in order to adhere the metal containing oxidizing agent and reducing agent to the substrate. The additive materials may also function as gelling agents, thixotropic agents or surfactants. Examples of binding materials include nitrocellulose, polyvinyl alcohol, diatomaceous earth, glass beads, colloidal silica, and a clay gelling agent.

In some embodiments, the binder is Laponite®, and in particular Laponite® RDS, as an inert additive material. Laponite® is a synthetic layered silicate, and in particular a magnesium phyllosilicate, with a structure resembling that of the natural clay mineral hectorite (Na_(0.4)Mg_(2.7)Li_(0.3)Si₄O₁₀(OH)₂). Laponite® RD is a commercial grade material which, when added to water, rapidly disperses to form a gel when hydrated (Southern Clay Products, Gonzales, Tex.). Laponite® RD has the following chemical analysis in weight percent: 59.5% SiO₂: 27.5% MgO: 0.8% Li₂O: 2.8% Na₂O. Laponite® RDS (Southern Clay Products, Gonzales, Tex.) is a commercially available sol-forming grade of Laponite® modified with a polyphosphate dispersing agent, or peptizer, to delay rheological activity until the Laponite® RDS is added as a dispersion into a formulation. A sol refers to a colloid having a continuous liquid phase in which solid is suspended in a liquid. Laponite® RDS has the following chemical analysis in weight percent: 54.5% SiO₂: 26% MgO: 0.8% Li₂O: 5.6% Na₂O: 4.1% P₂O₅. In the presence of electrolytes, Laponites® can act as gelling and thixotropic agents. Thixotropy refers to the property of a material to exhibit decreased viscosity under shear.

When incorporated into a solid fuel composition comprising a metal reducing agent and a metal-containing oxidizing agent, such as any of those disclosed herein, in addition to imparting gelling and thixotropic properties, Laponite® RDS can also act as binder. A binder refers to an additive that produces bonding strength in a final product. The binder can impart bonding strength, for example, by forming a bridge, film, matrix, or chemically self-react or react with other constituents of the formulation.

The binder may include other inorganic silicate based binders in addition to Laponite®.

The solid fuel layer is formed into a slurry by combining the metal reducing agent, metal containing oxidizing agent and binder and may be applied to a substrate by tip dispensing, spraying, screen printing or Meyer bar coding. The solid fuel layer is typically applied as a single coat and dried at an elevated temperature of between 40-200° C., as appropriate.

In some embodiments, for example, when the solid fuel is disposed on a substrate as a film or thin layer, wherein the thickness of the thin layer of solid fuel can range from 20 μm to 6000 μm, it can be useful that the solid fuel adhere to the surface of the substrate and that the constituents of the solid fuel adhere to each other, and maintain physical integrity. In some embodiments, it can be useful that the solid fuel remain adhered to the substrate surface and maintain physical integrity during processing, storage, and use during which time the solid fuel coating can be exposed to a variety of mechanical and environmental conditions. Several additives, such as those disclosed herein, can be incorporated into the solid fuel to impart adhesion and physical robustness to the solid fuel coating.

Other useful additive materials include glass beads, diatomaceous earth, nitrocellulose, polyvinyl alcohol, and other polymers that may function as binders. In certain embodiments, the solid fuel can comprise more than one additive material. The components of the solid fuel comprising the metal, oxidizing agent or additive material or any appropriate aqueous- or organic-soluble binder, can be mixed by any appropriate physical or mechanical method to achieve a useful level of dispersion or homogeneity. In some embodiments, the solid fuel can be degassed.

In some embodiments, the solid fuel layer comprises by weight 10-90% zirconium, 10-90% metal containing oxidizing agent and 1-15% binder, such as Laponite®. In other embodiments the solid fuel layer comprises by weight 40-70% zirconium, 10-40% metallic oxidizing agent and 3-10% binder.

In some embodiments, a solid fuel can be machined, molded, pre-formed or packed. The solid fuel can be formed as a separate element configured to be inserted into a heating unit, or the solid fuel can be applied directly to a heating unit. In some embodiments, a solid fuel can be coated, applied, or deposited directly onto a substrate forming part of a heating unit, onto a support that can be incorporated into a heating unit, or onto a support configured to transfer the solid fuel to a substrate forming a heating unit.

Referring to FIG. 1, a first electrode 22 is coupled to the substrate 12 and a second electrode 24 is coupled to a solid fuel surface 26 of the solid fuel layer 20 without an igniter or starter. The electrodes 22, 24 are in turn coupled to opposite leads of a power supply 28. A voltage can be selectively applied between the substrate 16 and the solid fuel surface 26 by selective closing of the switch 30.

Application of a voltage across certain solid fuel layer compositions is surprisingly found to propagate a sustaining exothermic metal oxidation-reduction reaction in the solid fuel layer 20 without an igniter or starter. Once a portion of the solid fuel layer is ignited, the heat generated by the oxidation-reduction reaction ignites adjacent unburned fuel until all the fuel is consumed in the process of the chemical reaction. Without being bound by theory, we can postulate that the metal oxide, the metal reducing agent or the binder may possess capacitive properties such that upon application of the voltage to the conductive substrate and the solid fuel layer, electrical energy is stored in the capacitive material until the buildup of potential (or voltage) results in electrical arcing occurring on a nanoscale between gaps in particles in the solid fuel coating. This arcing initiates an oxidation of air in the nanoscale gap creating enough heat to propagate the metal oxidation-reduction reaction.

The voltage and current necessary to propagate the reaction appear to be minimal. For example, a 9-volt battery has been used as the power supply and has successfully propagated the oxidation-reduction reaction. Other possible power supplies include conductive film coupled to a capacitor, a thin film battery and a lithium battery.

FIG. 3 is another embodiment of a heating unit wherein the solid fuel layer 20 is sandwiched between a pair of electrically conductive substrates 12. The electrically conductive substrates 12 are otherwise electrically insulated from one another. The first electrode 22 is coupled to a substrate and the second electrode 24 is coupled to the other substrate 12. In the same manner described above, application of the voltage across the substrates induces the self sustained metal oxidation-reduction reaction.

FIG. 4 is another embodiment showing a plurality of solid fuel layers 20 disposed on a substrate 12. In this embodiment the first electrode 22 is coupled to the substrate 12 and the second electrode 24 is selectively coupled to discrete solid fuel layers 20 so that upon application of a voltage across the solid fuel layers 20 the metal oxidation-reduction reaction is propagated by closing the switch 30. Selective coupling of the second electrode 24 to the various solid fuel layers 20 is illustrated by ghost lines in FIG. 4.

Some embodiments may include a drug supply unit comprising the heating unit described above. The drug supply unit can be used in a drug delivery device where a drug is to be thermally vaporized and then condensed for administration to a user. In some embodiments, the drug condensate can be administered by inhalation, nasal ingestion or topically. “Drug” refers to any compound for therapeutic use or non-therapeutic use, including therapeutic agents or substances. “Therapeutic agent” refers to any compound for use in the diagnosis, cure, mitigation, treatment or prevention of disease, and any compound used in the mitigation or treatment of symptoms of disease. “Non-therapeutic agent,” on the other hand, refers to compounds used for non-therapeutic use, typically for a recreational or experimental purpose. Referring to FIG. 1, the heating unit is converted to a drug supply unit by providing a film of a drug 38 on an exterior surface 16 of the substrate 12.

In some embodiments, the film 38 can be applied to exterior substrate surface 16 by any appropriate method and can depend at least in part on the physical properties of the drug and the final thickness of the film. In certain embodiments, methods of applying a drug to the exterior substrate surface include, but are not limited to, brushing, dip coating, spray coating, screen printing, roller coating, inkjet printing, vapor-phase deposition, spin coating, and the like. In some embodiments, the drug can be prepared as a solution comprising at least one solvent and applied to the exterior surface. In some embodiments, a solvent can comprise a volatile solvent such as, for example, but not limitation, acetone or isopropanol. In some embodiments, the drug can be applied to the exterior surface of the substrate as a melt. In some embodiments, the drug can be applied to a support having a release coating and transferred to a substrate from the support. For drugs that are liquid at room temperature, thickening agents can be admixed with the drug to produce a viscous composition comprising the drug that can be applied to the exterior substrate surface by any appropriate method, including those described herein. In some embodiments, a film of compound can be formed during a single application or can be formed during repeated applications to increase the final thickness of the film. In some embodiments, the final thickness of a film of drug disposed on the exterior substrate surface can be less than 60 μm, in some embodiments less than 20 μm and in some embodiments less than 10 μm, in some embodiments the film thickness can range from 0.02 μm to 20 μm, and in some embodiments can range from 0.1 μm to 10 μm.

In some embodiments, the film can comprise a therapeutically effective amount of at least one drug. Therapeutically effective amount refers to an amount sufficient to affect treatment when administered to a patient or user in need of treatment. Treating or treatment of any disease, condition, or disorder refers to arresting or ameliorating a disease, condition or disorder, reducing the risk of acquiring a disease, condition or disorder, reducing the development of a disease, condition or disorder or at least one of the clinical symptoms of the disease, condition or disorder, or reducing the risk of developing a disease, condition or disorder or at least one of the clinical symptoms of a disease or disorder. Treating or treatment also refers to inhibiting the disease, condition or disorder, either physically, e.g. stabilization of a discernible symptom, physiologically, e.g., stabilization of a physical parameter, or both, and inhibiting at least one physical parameter that may not be discernible to the patient. Further, treating or treatment refers to delaying the onset of the disease, condition or disorder or at least symptoms thereof in a patient which may be exposed to or predisposed to a disease, condition or disorder even though that patient does not yet experience or display symptoms of the disease, condition or disorder. In some embodiments, the drug film can comprise one or more pharmaceutically acceptable carriers, adjuvants, or excipients. Pharmaceutically acceptable refers to approved or approvable by a regulatory agency of the Federal or a state government or listed in the U.S Pharmacopoeia or other generally recognized pharmacopoeia for use in animals, and more particularly in humans.

The drug supply unit is configured such that the solid fuel heats a portion of the exterior surface of the substrate to a temperature sufficient to thermally vaporize the drug in certain embodiments within at least 3 seconds following ignition of the solid fuel, in other embodiments within 1 second following ignition of the solid fuel, in other embodiments within 800 milliseconds following ignition of the solid fuel, in other embodiments within 500 milliseconds following ignition of the solid fuel, and in other embodiments within 250 milliseconds following ignition of the solid fuel.

In some embodiments, a drug supply unit can generate an aerosol comprising a drug that can be inhaled directly by a user or can be mixed with a delivery vehicle, such as a gas, to produce a stream for delivery, e.g., via a spray nozzle, to a topical site for a variety of treatment regimens, including acute or chronic treatment of a skin condition, administration of a drug to an incision site during surgery, or to an open wound.

In some embodiments, rapid vaporization of a drug film can occur with minimal thermal decomposition of the drug. For example, in some embodiments, less than 10% of the drug is decomposed during thermal vaporization, and in some embodiments, less than 5% of the drug is decomposed during thermal vaporization. In some embodiments, a drug can undergo a phase transition to a liquid state and then to a gaseous state, or can sublime, i.e., pass directly from a solid state to a gaseous state. In some embodiments, a drug can include a pharmaceutical compound. In some embodiments, the drug can comprise a therapeutic compound or a non-therapeutic compound. Classes of drugs that can be used include, but are not limited to, anesthetics, anticonvulsants, antidepressants, antidiabetic agents, antidotes, antiemetics, antihistamines, anti-infective agents, antineoplastics, antiparkisonian drugs, antirheumatic agents, antipsychotics, anxiolytics, appetite stimulants and suppressants, blood modifiers, cardiovascular agents, central nervous system stimulants, drugs for Alzheimer's disease management, drugs for cystic fibrosis management, diagnostics, dietary supplements, drugs for erectile dysfunction, gastrointestinal agents, hormones, drugs for the treatment of alcoholism, drugs for the treatment of addiction, immunosuppressives, mast cell stabilizers, migraine preparations, motion sickness products, drugs for multiple sclerosis management, muscle relaxants, nonsteroidal anti-inflammatories, opioids, other analgesics and stimulants, opthalmic preparations, osteoporosis preparations, prostaglandins, respiratory agents, sedatives and hypnotics, skin and mucous membrane agents, smoking cessation aids, Tourette's syndrome agents, urinary tract agents, and vertigo agents.

Examples of anesthetic include ketamine and lidocaine.

Examples of anticonvulsants include compounds from one of the following classes: GABA analogs, tiagabine, vigabatrin; barbiturates such as pentobarbital; benzodiazepines such as clonazepam; hydantoins such as phenyloin; phenyltriazines such as lamotrigine; miscellaneous anticonvulsants such as carbamazepine, topiramate, valproic acid, and zonisamide.

Examples of antidepressants include amitriptyline, amoxapine, benmoxine, butriptyline, clomipramine, desipramine, dosulepin, doxepin, imipramine, kitanserin, lofepramine, medifoxamine, mianserin, maprotoline, mirtazapine, nortriptyline, protriptyline, trimipramine, venlafaxine, viloxazine, citalopram, cotinine, duloxetine, fluoxetine, fluvoxamine, milnacipran, nisoxetine, paroxetine, reboxetine, sertraline, tianeptine, acetaphenazine, binedaline, brofaromine, cericlamine, clovoxamine, iproniazid, isocarboxazid, moclobemide, phenyhydrazine, phenelzine, selegiline, sibutramine, tranylcypromine, ademetionine, adrafinil, amesergide, amisulpride, amperozide, benactyzine, bupropion, caroxazone, gepirone, idazoxan, metralindole, milnacipran, minaprine, nefazodone, nomifensine, ritanserin, roxindole, S-adenosylmethionine, escitalopram, tofenacin, trazodone, tryptophan, and zalospirone.

Examples of antidiabetic agents include pioglitazone, rosiglitazone, and troglitazone.

Examples of antidotes include edrophonium chloride, flumazenil, deferoxamine, nalmefene, naloxone, and naltrexone.

Examples of antiemetics include alizapride, azasetron, benzquinamide, bromopride, buclizine, chlorpromazine, cinnarizine, clebopride, cyclizine, diphenhydramine, diphenidol, dolasetron, droperidol, granisetron, hyoscine, lorazepam, dronabinol, metoclopramide, metopimazine, ondansetron, perphenazine, promethazine, prochlorperazine, scopolamine, triethylperazine, trifluoperazine, triflupromazine, trimethobenzamide, tropisetron, domperidone, and palonosetron.

Examples of antihistamines include astemizole, azatadine, brompheniramine, carbinoxamine, cetrizine, chlorpheniramine, cinnarizine, clemastine, cyproheptadine, dexmedetomidine, diphenhydramine, doxylamine, fexofenadine, hydroxyzine, loratidine, promethazine, pyrilamine and terfenidine.

Examples of anti-infective agent include compounds selected from one of the following classes: antivirals such as efavirenz; AIDS adjunct agents such as dapsone; aminoglycosides such as tobramycin; antifungals such as fluconazole; antimalarial agents such as quinine; antituberculosis agents such as ethambutol; β-lactams such as cefinetazole, cefazolin, cephalexin, cefoperazone, cefoxitin, cephacetrile, cephaloglycin, cephaloridine; cephalosporins, such as cephalosporin C, cephalothin; cephamycins such as cephamycin A, cephamycin B, and cephamycin C, cephapirin, cephradine; leprostatics such as clofazimine; penicillins such as ampicillin, amoxicillin, hetacillin, carfecillin, carindacillin, carbenicillin, amylpenicillin, azidocillin, benzylpenicillin, clometocillin, cloxacillin, cyclacillin, methicillin, nafcillin, 2-pentenylpenicillin, penicillin N, penicillin O, penicillin S, penicillin V, dicloxacillin; diphenicillin; heptylpenicillin; and metampicillin; quinolones such as ciprofloxacin, clinafloxacin, difloxacin, grepafloxacin, norfloxacin, ofloxacine, temafloxacin; tetracyclines such as doxycycline and oxytetracycline; miscellaneous anti-infectives such as linezolide, trimethoprim and sulfamethoxazole.

Examples of anti-neoplastic agents include droloxifene, tamoxifen, and toremifene.

Examples of antiparkisonian drugs include amantadine, baclofen, biperiden, benztropine, orphenadrine, procyclidine, trihexyphenidyl, levodopa, carbidopa, andropinirole, apomorphine, benserazide, bromocriptine, budipine, cabergoline, eliprodil, eptastigmine, ergoline, galanthamine, lazabemide, lisuride, mazindol, memantine, mofegiline, pergolide, piribedil, pramipexole, propentofylline, rasagiline, remacemide, ropinerole, selegiline, spheramine, terguride, entacapone, and tolcapone.

Examples of antirheumatic agents include diclofenac, hydroxychloroquine and methotrexate.

Examples of antipsychotics include acetophenazine, alizapride, amisulpride, amoxapine, amperozide, aripiprazole, benperidol, benzquinamide, bromperidol, buramate, butaclamol, butaperazine, carphenazine, carpipramine, chlorpromazine, chlorprothixene, clocapramine, clomacran, clopenthixol, clospirazine, clothiapine, clozapine, cyamemazine, droperidol, flupenthixol, fluphenazine, fluspirilene, haloperidol, loxapine, melperone, mesoridazine, metofenazate, molindrone, olanzapine, penfluridol, pericyazine, perphenazine, pimozide, pipamerone, piperacetazine, pipotiazine, prochlorperazine, promazine, quetiapine, remoxipride, risperidone, sertindole, spiperone, sulpiride, thioridazine, thiothixene, trifluperidol, triflupromazine, trifluoperazine, ziprasidone, zotepine, and zuclopenthixol.

Examples of anxiolytics include alprazolam, bromazepam, oxazepam, buspirone, hydroxyzine, mecloqualone, medetomidine, metomidate, adinazolam, chlordiazepoxide, clobenzepam, flurazepam, lorazepam, loprazolam, midazolam, alpidem, alseroxlon, amphenidone, azacyclonol, bromisovalum, captodiamine, capuride, carbcloral, carbromal, chloral betaine, enciprazine, flesinoxan, ipsapiraone, lesopitron, loxapine, methaqualone, methprylon, propanolol, tandospirone, trazadone, zopiclone, and zolpidem.

An example of an appetite stimulant is dronabinol.

Examples of appetite suppressants include fenfluramine, phentermine and sibutramine.

Examples of blood modifiers include cilostazol and dipyridamol.

Examples of cardiovascular agents include benazepril, captopril, enalapril, quinapril, ramipril, doxazosin, prazosin, clonidine, labetolol, candesartan, irbesartan, losartan, telmisartan, valsartan, disopyramide, flecanide, mexiletine, procainamide, propafenone, quinidine, tocainide, amiodarone, dofetilide, ibutilide, adenosine, gemfibrozil, lovastatin, acebutalol, atenolol, bisoprolol, esmolol, metoprolol, nadolol, pindolol, propranolol, sotalol, diltiazem, nifedipine, verapamil, spironolactone, bumetanide, ethacrynic acid, furosemide, torsemide, amiloride, triamterene, and metolazone.

Examples of central nervous system stimulants include amphetamine, brucine, caffeine, dexfenfluramine, dextroamphetamine, ephedrine, fenfluramine, mazindol, methyphenidate, pemoline, phentermine, sibutramine, and modafinil.

Examples of drugs for Alzheimer's disease management include donepezil, galanthamine and tacrin.

Examples of drugs for cystic fibrosis management include CPX (ciprofloxacin), IBMX (3-isobutyl-1-methylxanthine), XAC and analogues; 4-phenylbutyric acid; genistein and analogous isoflavones; and milrinone.

Examples of diagnostic agents include adenosine and aminohippuric acid.

Examples of dietary supplements include melatonin and vitamin-E.

Examples of drugs for erectile dysfunction include tadalafil, sildenafil, vardenafil, apomorphine, apomorphine diacetate, phentolamine, and yohimbine.

Examples of gastrointestinal agents include loperamide, atropine, hyoscyamine, famotidine, lansoprazole, omeprazole, and rebeprazole.

Examples of hormones include: testosterone, estradiol, and cortisone.

Examples of drugs for the treatment of alcoholism include naloxone, naltrexone, and disulfiram.

Examples of drugs for the treatment of addiction it is buprenorphine.

Examples of immunosupressives includemycophenolic acid, cyclosporin, azathioprine, tacrolimus, and rapamycin.

Examples of mast cell stabilizers include cromolyn, pemirolast, and nedocromil.

Examples of drugs for migraine headache include almotriptan, alperopride, codeine, dihydroergotamine, ergotamine, eletriptan, frovatriptan, isometheptene, lidocaine, lisuride, metoclopramide, naratriptan, oxycodone, propoxyphene, rizatriptan, sumatriptan, tolfenamic acid, zolmitriptan, amitriptyline, atenolol, clonidine, cyproheptadine, diltiazem, doxepin, fluoxetine, lisinopril, methysergide, metoprolol, nadolol, nortriptyline, paroxetine, pizotifen, pizotyline, propanolol, protriptyline, sertraline, timolol, and verapamil.

Examples of motion sickness products include diphenhydramine, promethazine, and scopolamine.

Examples of drugs for multiple sclerosis management include bencyclane, methylprednisolone, mitoxantrone, and prednisolone.

Examples of muscle relaxants include baclofen, chlorzoxazone, cyclobenzaprine, methocarbamol, orphenadrine, quinine, and tizanidine.

Examples of nonsteroidal anti-inflammatory drugs include aceclofenac, acetaminophen, alminoprofen, amfenac, aminopropylon, amixetrine, aspirin, benoxaprofen, bromfenac, bufexamac, carprofen, celecoxib, choline, salicylate, cinchophen, cinmetacin, clopriac, clometacin, diclofenac, diflunisal, etodolac, fenoprofen, flurbiprofen, ibuprofen, indomethacin, indoprofen, ketoprofen, ketorolac, mazipredone, meclofenamate, nabumetone, naproxen, parecoxib, piroxicam, pirprofen, rofecoxib, sulindac, tolfenamate, tolmetin, and valdecoxib.

Examples of opioid drugs include alfentanil, allylprodine, alphaprodine, anileridine, benzylmorphine, bezitramide, buprenorphine, butorphanol, carbiphene, cipramadol, clonitazene, codeine, dextromoramide, dextropropoxyphene, diamorphine, dihydrocodeine, diphenoxylate, dipipanone, fentanyl, hydromorphone, L-alpha acetyl methadol, lofentanil, levorphanol, meperidine, methadone, meptazinol, metopon, morphine, nalbuphine, nalorphine, oxycodone, papaveretum, pethidine, pentazocine, phenazocine, remifentanil, sufentanil, and tramadol.

Examples of other analgesic drugs include apazone, benzpiperylon, benzydramine, caffeine, clonixin, ethoheptazine, flupirtine, nefopam, orphenadrine, propacetamol, and propoxyphene.

Examples of opthalmic preparation drugs include ketotifen and betaxolol.

Examples of osteoporosis preparation drugs alendronate, estradiol, estropitate, risedronate and raloxifene.

Examples of prostaglandin drugs include epoprostanol, dinoprostone, misoprostol, and alprostadil.

Examples of respiratory agents include albuterol, ephedrine, epinephrine, fomoterol, metaproterenol, terbutaline, budesonide, ciclesonide, dexamethasone, flunisolide, fluticasone propionate, triamcinolone acetonide, ipratropium bromide, pseudoephedrine, theophylline, montelukast, zafirlukast, ambrisentan, bosentan, enrasentan, sitaxsentan, tezosentan, iloprost, treprostinil, and pirfenidone

Examples of sedative and hypnotic drugs include butalbital, chlordiazepoxide, diazepam, estazolam, flunitrazepam, flurazepam, lorazepam, midazolam, temazepam, triazolam, zaleplon, zolpidem, and zopiclone.

Examples of skin and mucous membrane agents include isotretinoin, bergapten and methoxsalen.

Examples of smoking cessation aids include nicotine and varenicline.

An example of a Tourette's syndrome agent includes pimozide.

Examples of urinary tract agents include tolteridine, darifenicin, propantheline bromide, and oxybutynin.

Examples of vertigo agents include betahistine, indolizine and meclizine.

In certain embodiments, a drug can further comprise substances to enhance, modulate or control release, aerosol formation, intrapulmonary delivery, therapeutic efficacy, therapeutic potency, stability, and the like. For example, to enhance therapeutic efficacy a drug can be co-administered with one or more active agents to increase the absorption or diffusion of the first drug through the pulmonary alveoli, or to inhibit degradation of the drug in the systemic circulation. In certain embodiments, a drug can be co-administered with active agents having pharmacological effects that enhance the therapeutic efficacy of the drug. In certain embodiments, a drug can comprise compounds that can be used in the treatment of one or more diseases, conditions, or disorders. In certain embodiments, a drug can comprise more than one compound for treating one disease, condition, or disorder, or for treating more than one disease, condition, or disorder.

The embodiment of FIG. 4 has multiple solid fuel layers 20 suitable for a multidose drug supply unit by application of discrete layers of drugs 38 opposite the solid fuel layers 20. By selectively applying the electrode 24 to the solid fuel layers 20, corresponding discrete drug layers 38 can be vaporized.

FIG. 5 is a schematic representation of a drug delivery device 40. The drug delivery device 40 can be used in combination with any of the drug supply units illustrated in FIGS. 1-4 or described herein. The drug delivery device 40 comprises a housing 42 surrounding a drug supply unit 10 and the housing 42 defines an airway 44. In use, air can be drawn through the housing 42 via the airway 44 by drawing air in through the inlet 46 in the direction of the arrow 48 to the outlet 50. In use, a drug layer 38 is vaporized and the vaporized drug is entrained in the air and then condenses to form an aerosol in the condensation space 52 so that a condensation aerosol can be delivered through the outlet 50. As described in the '914 publication, the drug delivery device can be configured and dimensioned to provide required airflow rates for forming aerosol particles of select size from various drugs.

Examples and Data

Below a number of examples of formulations and variations in parameters used in building and testing heating units in accordance with the disclosure herein are set forth. Variation of at least the following parameters have been found to effect the energy requirements necessary to initiate the metal oxidation-reduction reaction:

-   -   1. Adjustment of the formulation of the solid fuel;     -   2. Varying the thickness of the solid fuel coating;     -   3. Pressure of contact between the solid fuel and an electrode;     -   4. Pulse duration of energy delivery;     -   5. Resistance of the formulation;     -   6. Voltage applied between the surface of the solid fuel and the         conductive substrate; and     -   7. Where the energy source is a capacitor, the capacitance of         the capacitor.

Four different solid fuel formulations were made using the indicated relative weight percentages of manganese (MnO₂), ferric oxide (Fe₂O₃) and zirconium (Zr) set forth in FIG. 6. In addition, essentially the same weight percentage of Laponite® formulation (in a range of 2-10% of the total weight) was part of the formulations, though it is not indicated in FIG. 6. The various solid fuel formulations were then connected to a power supply comprising a 10 volt, 1000 microfarad capacitor. FIG. 7 demonstrates which formulations were actuated by the power supply and the measured resistance of the solid fuel.

Other formulations of metal oxides and metal reducing agent that could be activated by application of a voltage included copper oxide (Cu₂O) and zirconium; copper (II) oxide (CuO) and zirconium; molybdenum trioxide (MoO₃) and zirconium; ferric oxide (Fe₂O₃) and zirconium; ferric oxide (Fe₂O₃), manganese dioxide (MnO₂) and zirconium; and ferric oxide (Fe₂O₃), manganese dioxide (MnO₂), plus nano carbon particles. Formulations that failed to activate included zinc oxide (ZnO) and zirconium (presumably because ZnO has a high melting point), a pure Zr coating and a pure Ti coating.

Tests showed that reliability of the solid fuel ignition by application of a 10 v, 1000 μF capacitor improved markedly when the solid fuel resistance was lower than one million ohms. This is demonstrated by the data charted in FIG. 8.

Varying the starter area did not appear to improve resistance. This is illustrated by the data plotted in FIG. 9.

Data collected investigating the effectiveness of the reactive coating interestingly showed that to a point, increasing reactant thickness initially lowered the voltage required for activation. In this example the reactant contained the following relative dry weight percentage ratios of Zr, Fe₂O₃ and MnO₂:

-   -   ZR_(AB)—66.24%     -   Fe₂O₃—25.76%     -   MnO₂—8%         In addition, as with other examples, the formula included 2-10%         by weight Laponite® based on the total weight of the         formulation. FIG. 10 shows, surprisingly, that as the thickness         of the solid fuel increased, activation of the solid fuel         required a lower voltage. The indicated voltage was provided by         a power supply delivered for 50 μs.

Using the same formulation described above, collected data demonstrated that higher voltage capacitors having lower capacitance would also readily ignite the solid fuel layer. This is demonstrated by the three graphs set forth in FIGS. 11A-11C.

FIG. 12 is a graph of thickness of the solid fuel (or reactant) to the capacitance of a capacitor for a variety of capacitor voltages, again using the same reactant formulation 66.24% Zr:25.76% Fe2O3:8% MnO2, percentages by dry weight ratio. This graph illustrates two things. First, using higher voltage capacitors lowers the required capacitance of the capacitors. Second, increasing the thickness of the reactant improved activation. However, it should be noted that at some point reactant thickness will inhibit activation. Activation energy was as low as 0.18 mJ.

Collected data set forth in FIG. 13 showed that as the voltage of a capacitor increased the required capacitance of the capacitor decreased over a range of solid fuel thicknesses of approximately 20 μm to 49 μm. In addition, by varying reactant thickness and the voltage of the capacitor, the energy required to initiate the solid fuel could vary from as low as 0.2 mJ to 11.25 mJ. The heat units tested were two-sided heat units having a steel lead contacting the solid fuel. The heat units incorporated the reactant formulation: 66.24% Zr:25.76% Fe2O3:8% MnO2, percentages by dry weight ratio.

Heat units using a solid fuel capable of undergoing an exothermic metal oxidation-reduction reaction propagated without an igniter as disclosed and claimed herein dramatically reduce the number of components and processing steps required to make heat units and significantly reduces the cost. The heat units improve the safety of the device by eliminating a starter which typically generates high heat and potentially harmful gases. Heat units as described herein simplify the design and construction of multi-dose drug delivery devices. Furthermore, by simplifying and minimizing the elements necessary to activate oxidation-reduction reaction, the embodiments disclosed herein enhance the reliability of heat units and drug supply units utilizing the disclosed ignition system.

Various embodiments of the disclosure could also include permutations of the various elements recited in the claims as if each dependent claim was multiple dependent claim incorporating the limitations of each of the preceding dependent claims as well as the independent claims. Such permutations are expressly within the scope of this disclosure.

While the invention has been particularly shown and described with reference to a number of embodiments, it would be understood by those skilled in the art that changes in the form and details may be made to the various embodiments disclosed herein without departing from the spirit and scope of the invention and that the various embodiments disclosed herein are not intended to act as limitations on the scope of the claims. All references cited herein are incorporated in their entirety by reference. 

What is claimed is:
 1. A drug supply unit comprising: an electrically conductive substrate having an interior and an exterior surface; a solid fuel layer comprising a metal reducing agent, a metal containing oxidizing agent and an inorganic binder coated on at least a portion of the interior surface of the substrate, the solid fuel layer having a solid fuel surface spaced from the interior surface of the substrate; a drug layer capable of vaporization upon being heated to a select temperature coated on the exterior surface of the substrate; a first electrode coupled to the substrate; a second electrode coupled to the solid fuel surface; and a power supply configured to be selectively coupled to the first and second electrodes to provide a voltage between the electrically conductive substrate and the solid fuel surface.
 2. The drug supply unit of claim 1 wherein the electrically conductive substrate comprises a steel foil.
 3. The drug supply unit of claim 1 wherein the metal reducing agent is selected from at least one of the following: zirconium, titanium, aluminum and iron.
 4. The drug supply unit of claim 1 wherein the metal containing oxidizing agent is selected from at least one of MoO₃, Fe₂O₃, KClO₄ and KClO₃.
 5. The drug supply unit of claim 1 wherein the binder is selected from at least one of the following: nitrocellulose, polyvinyl alcohol, diatomaceous earth, glass beads, colloidal silica, and a clay gelling agent.
 6. The drug supply unit of claim 1 wherein the solid fuel layer comprises by weight 10-90% zirconium, 10-90% metal containing oxidizing agent and 1-15% binder.
 7. The drug supply unit of claim 1 wherein the solid fuel layer comprises by weight 40-70% zirconium, 10-40% metallic oxidizing agent and 3-10% binder.
 8. The drug supply unit of claim 1 further comprising a second metal substrate contacting the solid fuel layer surface and electrically insulated from the metal substrate, the second electrode being coupled to the second metal substrate.
 9. The drug supply unit of claim 1 further comprising a plurality of spaced solid fuel layers coated on the interior surface of the substrate and a corresponding composition layer in the exterior surface, the second electrode being configured for selectively coupling to a select solid fuel layer.
 10. The drug supply unit of claim 1 wherein the solid fuel has a thickness ranging from 20-49 μm.
 11. The drug supply unit of claim 1 wherein the solid fuel layer has a thickness of greater than 20 μm.
 12. The drug supply unit of claim 1 wherein the solid fuel layer has a resistance of less than 1,000,000Ω.
 13. The drug supply unit of claim 1 wherein the voltage is greater than 3 v.
 14. The drug supply unit of claim 1 wherein the voltage is between 4-30 v.
 15. The drug supply unit of claim 1 wherein an activation energy of less than 11.25 mJ is required.
 16. The drug supply unit of claim 1 wherein an activation energy of between about 0.18 mJ-11.25 mJ is required.
 17. An aerosol drug delivery device comprising: a housing defining an airway; and a drug supply unit disposed in the airway, the drug supply unit comprising: an electrically conductive substrate having an interior and an exterior surface, the exterior surface being exposed to the airway; a solid fuel layer comprising a metal reducing agent, a metal containing oxidizing agent and an inorganic binder coated on at least a portion of the interior surface of the substrate, the solid fuel layer having a solid fuel surface spaced from the interior surface of the substrate, the interior surface of the substrate being isolated from the airway; a drug layer capable of vaporization upon being heated to a select temperature coated on the exterior surface of the substrate; a first electrode coupled to the substrate; a second electrode coupled to the solid fuel surface; and a power supply configured to be selectively coupled to the first and second electrodes to provide a voltage between the electrically conductive substrate and the solid fuel surface. 